Support element and support element system, especially for concrete constructions and concrete nuilding components

ABSTRACT

The invention relates to a support element, especially for concrete constructions and concrete building components, comprising at least one supporting fiber system embedded in a binder. The aim of the invention is to provide a support element that comprises at least one supporting fiber system embedded in a binder and that is characterized by excellent vapor permeability and at the same time by high stability and good modulus E values. To this end, the binder contains at least one polymer component that has a specific water vapor diffusion resistance value μ of at least 20000, a modulus E of transverse elasticity G of at least 3000 N/mm 2  and a tensile strength of at least 10 N/mm 2 . The binder further contains at least one granular component that extends at least through parts of the supporting fiber system and that forms together with the supporting fiber system, in the cured state of the binder/polymer component, a solid body dispersoid with a water vapor diffusion resistance value μ of not more than 10000.

[0001] The invention relates to a support element and a support element configuration, in particular for concrete structures and concrete structural components, the support element comprising at least one fiber support embedded in a binder. In the case of the support element configuration relating to the object of the invention, the support element has been joined to a structure or structural element by adhesion.

[0002] Support elements and support element configurations of this kind are of the state of the art, for example, in the form of sets or fabrics of high-strength fibers which are applied with a binder in layers in the tensile stress zone of a concrete surface. Use is also made of appropriately prefabricated laminates which are applied by adhesion in the tensile stress zone of a concrete surface. Such use also extends to repairs of areas of cracks and fractures in load-bearing concrete structures, but also to reinforcement of structures which are strictly speaking still intact to enable them to absorb increased loads and to new structures to ensure absorption of concentrated loads, above all, for example, in spatially reduced circumstances. In these and other applications, concrete with a more or less high moisture content is generally present in the subsoil area of laminate support elements. Water and other moistening agents may also be present, whose long-term difflusion of which in the form of corresponding vapors would not be prevented by the laminar support elements or the hardened polymer binder components of such elements.

[0003] Conventional urethane-based polymers for binders are available which have a vapor permeability adequate for the present purposes when in the hardened state. Such binders do, however, have a shear-elasticity modulus which is very low in comparison to such moduli of the high-strength fiber laminates. Consequently, in many instances the fiber strength may not be fully used, since the binder with low shear resistance between the subsoil to be relieved and the laminate fibers and between the laminate fibers themselves, limits the load transmission to the fibers to values which are too low. This applies especially to prestressed fiber configurations. On the other hand, conventional binder polymers with modulus values suitable for the purposes in question, conventional epoxy binders in particular, are characterized by virtually no vapor permeability when in the hardened state.

[0004] A first object of the invention, then, is development of a support element which comprises at least one support fiber configuration embedded in a binder and is characterized by high vapor permeability accompanied by high strength and elasticity modulus values. The same applies to conglutination of subsoil and support element in relation to the additional object of the invention. The solution claimed for attainment of the first object of the invention is determined by the characteristics specified in claim 1, and that claimed for the additional object of the invention by the characteristics specified in claims 16 to 20.

[0005] In the case of the support element claimed for the invention, first a binder polymer component is assumed, one which itself has a water vapor difflusion resistance number μ of at least 20,000 when in the hardened state. This standard coefficient is a dimensionless quantity and indicates how much greater the water vapor diffusion permeability resistance of a layer of the material in question is than that of a layer of air of the same temperature at rest. Hence this is a material-specific parameter for water vapor. Consequently, it is directly authoritative for the relationships occurring in concrete engineering, but in theory—at least when considering parameter quotients for various materials—may also be used in certain cases as an approximation for kinds of vapor other than water vapor. For cured epoxy resins, for example, the μ value is around 10⁵, this in effect denoting impermeability, which renders these resins unsuitable as binders for purposes of structural reinforcement accompanied by final drying of the subsoil. On the other hand, epoxy resins have high potential as regards tensile strength and shear strength, and also as regards the shear elasticity modulus (high shear rigidity), something which makes them suitable by preference in reinforcement laminates, especially in the case of structures with high fiber pretensioning.

[0006] The advance claimed for the invention now comes into play. It is based on the finding that a composite structure of a support fiber configuration with a dispersoid binder of a polymer and a fine granulate in the viscous state worked into it permits the desired vapor permeability of the hardened composite even if the polymer is only very slightly or not at all vapor permeable. The support element claimed for the invention realizes a composite structure such as this. Practical embodiments and tests have shown that, as claimed for the invention, μ values distinctly below 10,000 have been achieved with composite support elements with high-strength fiber configurations and hardened dispersoid binders.

[0007] This applies with reproducible certainty not only in the case of binder polymer components with relatively low μ values of around 20,000 as initial material, but also in that of high-grade vapor-blocking polymers such as epoxy resins with μ values of about 75,000 and far above as initial material for the dispersoid binder.

[0008] Practical experience has surprisingly shown that relatively high upper limit values are possible for the binder-granulate components in the area of the support fiber configuration without impairing uniform and continuous working of the binder into the support fiber configuration. An upper grain size boundary value of 0.2 mm has accordingly been obtained, but it is preferable to adhere to such a value of 0.1 mm. Astounding dimensioning limits have also been found with respect to adjustment of proportions in the area of the binder granulate components configured for the support fibers relative to the polymer binder component, specifically, a portion corresponding to 35 percent by volume; for reasons of product safety, however, it may be recommended that a maximum of 15 percent by volume be adhered to, provided that the desired vapor permeability is achieved in the particular application. Certain value ranges have also been obtained with respect to optimization for the minimum portion in the area of the binder granulate components configured for the support fibers; specifically, such granulate components should not fall below a share of 7 percent by volume relative to the hardened polymer binder components, but preferably not below a minimum of 12 percent by volume.

[0009] In general mineral substances are to be considered for the binder granulate components. Those characterized by alkaline reactivity are of particular importance, however. After drying of the subsoil the alkaline granulate, in its fine distribution within the polymer binder components, comes into contact with air diffused inward from the exterior and can neutralize the carbon dioxide present in it. This contributes to maintenance of the alkaline nature in the concrete and accordingly suppression of corrosion effects on steel reinforcements in the concrete. In this connection pH values ranging from 9 to 12 are advantageous for the granulate. Binder granulates consisting at least in part of minerals of the “cement” type have proved to be highly effective both for the vapor permeability and for the alkaline reactivity in question. Such minerals should contain at least the components CaO, SiO₂, Al₂O₃, Fe₂O₃, or equivalent silicate forming agents.

[0010] It is important for the vapor permeability for the granulate component introduced into the binder mass in the area of the support fibers to have an open-pore structure, at least to some extent, as regards the grain surfaces. The permeability effect achieved and verified must be ascribable at least in part to the fact that the grain surfaces form a microscopic network of vapor diffusion channels which are nevertheless impermeable by liquid media because of the viscosity of the latter. In any event it is claimed for the invention that dispersoid binders possessing largely optimum combinations of properties may be prepared even by preference with highly vapor blocking epoxy resins which are yet extremely valuable from the viewpoint of strength and elasticity characteristics as binder polymer components.

[0011] It is claimed for the invention that optimization possibilities for the present application have also been created with respect to the support fiber configurations. Consequently, in addition to carbon and other high-strength fibers consideration may be given to support fiber configurations, primarily ones containing aramide fibers, preferably those containing an epoxy-based binder, permeated by a polymer binder component and a granulate binder component, and consisting at least in part of a high-strength polymer. Precisely such high-strength polymer fibers are by preference suited for preparation of support fiber configurations with strands and clusters, primarily in unidirectional configuration, but also preparation of tissues and the like with fibers or bundles of fibers twisted at least to some extent relative to each other. A configuration of the supporting elements such as this promotes uniformity of introduction of shearing stress into the individual fibers or bundle of fibers, and accordingly uniformity of distribution of stress over the cross-section of the support fiber configuration and is of importance above all in the case of prestressed configurations.

[0012] In a preferred embodiment of the support element, configurations claimed for the invention which are associated with a structure or structural component have a prestressed support fiber configuration with polymer binder components and granulate binder components, the support fiber configuration consisting at least partly of polymer fibers having a tensile strength of at least 1.2 and a tensile elasticity modulus ranging from a maximum of 150 Gpa to a minimum of 40 Gpa. In a high-grade combination of components such as this with pretensioned support fibers, specific significance is assigned to vapor permeability without impairing the long-term stability of the prestressing relationships. Especially optimal results have been obtained with structures in which the cross-section of the support fiber configuration consists at least to the extent of 15 percent of aramide fibers, which when subjected to prestressing corresponding to an elasticity minimum of 0.4 percent but maximum of 2.2 percent are shear-resistant when integrated with the subsoil. The cross-sectional component of the aramide fibers may be incresased to a minimum of 45 percent, and especially even to a minimum of 75 percent to meet extreme requirements. The respective remaining cross-section of the support fiber configuration may be occupied by fibers of a different type, for example, by ones of special deformation or flow properties, for the purpose of preparation of combined property profiles of the support element and/or of the support element configuration. By preference at least one part of the pretensioned polymer fibers extends at least in approximation parallel to a predetermined tensile load direction.

[0013] In a special support element configuration also forming part of the object of the invention, at least one support element, in particular but not mandatorily, such an element is combined with dispersoid binders, by conglutination with a structure or structural component. The conglutination element used for this purpose contains at least one polymer component which as such in the hardened state has a water vapor diffusion resistance number μ of at least 20,000, a shear elasticity modulus G of at least 5000 N/mm², and a tensile strength of at least 10 N/mm². The conglutination also contains a granulate component which forms with the polymer conglutination component a solid dispersoid with a water vapor diffusion resistance number μ of a maximum of 10,000.

[0014] It is to be regarded a distinctive feature of this configuration that the conglutination with the subsoil provided for the support element is in the form of a vapor-permeable dispersoid binder. This for practical application as well of essential significance, especially for prefabricated laminated fiber support elements to be combined with a structural component or structure in the solid state, which elements themselves may be more or less vapor-permeable, of course not necessarily as a result of use of a dispersoid binder. The passage of vapor through the support element would at the least be greatly impaired without the now available vapor permeability by means of dispersoid conglutination. 

1. A support element, especially for concrete structures and concrete construction components, having a support fiber configuration embedded in a binder, characterized by the following features: (a) the binder contains at least one polymer component which as such when in the hardened state has a specific water vapor diffusion resistance number μ of at least 20,000, a shear elasticity modulus G of at least 3000 N/mm², and a tensile strength of at least 10 N/mm²; (b) the binder contains at least one granulate component at least in part permeating the support fiber configuration, which granulate component forms with the support fiber configuration when the polymer binder component is in the hardened state a solid dispersoid with a water vapor diffusion resistance number μ of a maximum of 10,000.
 2. A support element as specified in claim 1, wherein the polymer binder component as such when in the hardened state has a water vapor diffusion resistance number μ of at least 75,000.
 3. A support element as specified in claim 1 or 2, wherein the granulate component has in the area of the support fiber configuration a maximum grain size of 0.2 mm, preferably of 0.1 mm.
 4. A support element as specified in one of the preceding claims, wherein the granulate binder component disposed in the area of the support fibers forms a portion of a maximum of 35 percent by volume relative to the hardened polymer binder component.
 5. A support element as specified in claim 4, wherein the granulate binder component disposed in the area of the support fibers forms a portion of a maximum of 15 percent by volume relative to the hardened polymer binder component.
 6. A support element as specified in one of the preceding claims, wherein the granulate binder component disposed in the area of the support fibers forms a portion of a minimum of 7 percent, in particular of a minimum of 12 percent, by volume relative to the hardened polymer binder component.
 7. A support element as specified in one of the preceding claims, characterized at least in part by a mineral binder-granulate component with alkaline reactivity.
 8. A support element as specified in claim 7, wherein the binder-granulate component has a pH value ranging from 9 to
 12. 9. A support element as specified in one of the preceding claims, characterized by a binder-granulate component intermingling with the support fiber configuration, which binder-granulate component consists at least in part of minerals of the “cement” type.
 10. A support element as specified in claim 9, wherein the binder-granulate component contains at least the compounds CaO, SiO₂, Al₂O₃, Fe₂O₃, or equivalent silicate formers.
 11. A support element as specified in one of the preceding claims, wherein the granulate component disposed in the area of the support fibers has within the binder mass, at least in part, an open-pore structure with respect to the grain surfaces.
 12. A support element as specified in one of the preceding claims, characterized by a binder-polymer component consisting at least in part of epoxy resin.
 13. A support element as specified in one of the preceding claims, characterized by a support fiber configuration consisting at least in part of high-strength polymer, such configuration being intermingled with a binder-polymer component and a binder-granulate component.
 14. A support element as specified in claim 13, characterized by a support fiber configuration which consists at least in part of aramide fibers and which is intermingled with a binder-polymer component consisting at least in part of a binder-polymer component consisting at least in part of epoxy resin and with a granulate binder component.
 15. A support element as specified in one of the preceding claims, characterized by a support fiber configuration which consists at least in part of fibers or bundles of fibers twisted relative to each other, in particular of high-strength polymer fibers.
 16. A support element configuration with at least one support element as specified in one of the preceding claims, the support element being connected to a structure or structural component, characterized in that the support element (T) has a pretensioned support fiber configuration which consists at least in part of polymer fibers with a tensile strength of at least 1.2 Mpa and with a tensile elasticity modulus ranging from a maximum of 150 Gpa to a minimum of 40 Gpa.
 17. A support element configuration as specified in claim 16, wherein the cross-section of the support fiber configuration consists to the extent of 15 percent of aramide fibers which are subjected to pretensioning corresponding to an elongation of a minimum of 0.4 percent but a maximum of 2.2 percent and are shear-resistantly joined to the subsoil.
 18. A support element configuration as specified in claim 17, wherein the cross-section of the support fiber configuration consists to the extent of at least 45 percent, preferably 75 percent, of aramide fibers.
 19. A support element configuration as specified in one of claims 16 to 18, wherein at least part of the pretensioned polymer fibers are oriented at least in approximation parallel to a predetermined tensile load direction.
 20. A support element configuration, in particular as specified in one of claims 16 to 19 and in particular having at least one support element as specified in one of claims 1 to 15, the support element having at least one support fiber configuration embedded in a binder and being joined to a structure or structural component by adhesion, such configuration being characterized by a combination of the following characteristics: (a) the adhesive element contains at least one polymer component which as such has in the hardened state a water vapor difflusion resistance number μ of at least 20,000, a shear elasticity modulus G of at least 5000 N/mm², and a tensile strength of at least 10 N/mm²; (b) the adhesive element contains a granulate component which forms with the adhesive element-polymer component a solid-dispersoid with a water vapor diffusion resistance number μ of a maximum of 10,000. 